Installation, Operation and Maintenance Manual...If the unit contains lubricating fluid, take appropriate measures to prevent the dispersion of leaks into the environment. 1 Introduction

Installation, Operation and

Maintenance Manual

e-HM SeriesMultistage Horizontal Pump Unit

Table of Contents

1 Introduction and Safety..............................................................................................................31.1 Introduction.......................................................................................................................... 3

1.1.1 Purpose of this manual.................................................................................................31.1.2 Supplementary instructions.........................................................................................3

1.2 Safety..................................................................................................................................... 31.2.1 Danger levels and safety symbols.............................................................................. 31.2.2 User safety......................................................................................................................41.2.3 Protection of the environment.................................................................................... 41.2.4 Sites exposed to ionizing radiations...........................................................................5

2 Transport and storage................................................................................................................62.1 Handling of the packed unit............................................................................................... 62.2 Unit inspection upon delivery............................................................................................ 7

2.2.1 Inspect the package..................................................................................................... 72.2.2 Unpacking and inspection of the unit........................................................................ 7

2.3 Unit handling........................................................................................................................ 72.4 Storage.................................................................................................................................. 8

2.4.1 Storage of the packed unit.......................................................................................... 82.4.2 Long-term storage of the unit..................................................................................... 8

3 Product Description....................................................................................................................93.1 Designation...........................................................................................................................93.2 Data plate..............................................................................................................................9

3.2.1 Marks of safety approval............................................................................................113.3 Denomination of the main components.........................................................................123.4 Intended use.......................................................................................................................13

3.4.1 Pumped liquids...........................................................................................................133.5 Improper use......................................................................................................................14

3.5.1 Examples of improper use.........................................................................................143.5.2 Examples of improper installation............................................................................14

3.6 Use in water distribution networks for human consumption....................................... 14

4 Installation................................................................................................................................. 164.1 Precautions......................................................................................................................... 164.2 Mechanical installation......................................................................................................16

4.2.1 Installation area...........................................................................................................164.2.2 Permitted positions.................................................................................................... 174.2.3 Fastening of the unit...................................................................................................174.2.4 Reducing vibrations....................................................................................................17

4.3 Hydraulic connection........................................................................................................ 184.3.1 Guidelines for the hydraulic system......................................................................... 18

4.4 Electrical connection......................................................................................................... 204.4.1 Ground.........................................................................................................................204.4.2 Guidelines for electrical connection........................................................................ 204.4.3 Guidelines for the electric panel...............................................................................204.4.4 Motor guidelines.........................................................................................................214.4.5 Operation with frequency converter........................................................................22

5 Operation.................................................................................................................................. 235.1 Precautions......................................................................................................................... 23

Table of Contents

e-HM Series Installation, Operation and Maintenance Manual 1

5.2 Filling - Priming.................................................................................................................. 245.2.1 Positive suction head installation..............................................................................245.2.2 Suction lift installation................................................................................................ 24

5.3 Checking the direction of rotation (three-phase motors).............................................255.3.1 Wrong rotation direction........................................................................................... 25

5.4 Start-up................................................................................................................................265.4.1 Settling of the mechanical seal................................................................................. 26

5.5 Stopping............................................................................................................................. 27

6 Maintenance..............................................................................................................................286.1 Precautions......................................................................................................................... 286.2 Maintenance every 4000 hours of operation or every year......................................... 286.3 Long periods of inactivity..................................................................................................296.4 Ordering spare parts.........................................................................................................29

7 Troubleshooting....................................................................................................................... 307.1 Precautions......................................................................................................................... 307.2 The unit does not start...................................................................................................... 307.3 The differential protection device (RCD) is activated....................................................307.4 The motor thermal overload protection or the fuses trigger when the unit starts....307.5 The thermal motor protection trips................................................................................. 317.6 The unit runs but there is little or no flow rate............................................................... 317.7 When turned off, the unit turns in the opposite direction............................................317.8 The unit produces excessive noise and/or vibrations...................................................317.9 The unit starts up too frequently (automatic start/stop)............................................... 327.10 The unit never stops (automatic start/stop)..................................................................327.11 The unit is leaking............................................................................................................327.12 The motor becomes excessively hot.............................................................................337.13 The frequency converter (if present) is in error mode or turned off.........................33

8 Technical references................................................................................................................ 348.1 Operating environment.................................................................................................... 34

8.1.1 Temperature................................................................................................................348.1.2 Relative air humidity................................................................................................... 348.1.3 Elevation...................................................................................................................... 34

8.2 Temperature of pumped liquid....................................................................................... 348.3 Operating pressure........................................................................................................... 358.4 Maximum hourly start-ups................................................................................................ 358.5 Protection class.................................................................................................................. 358.6 Electrical specifications..................................................................................................... 358.7 Permitted tolerances for the supply voltage.................................................................. 358.8 Noise level.......................................................................................................................... 358.9 Materials..............................................................................................................................36

9 Disposal..................................................................................................................................... 379.1 Precautions......................................................................................................................... 37

10 Declarations............................................................................................................................ 3810.1 EC Declaration of Conformity (Original).......................................................................3810.2 EU Conformity Declaration (n. EMCD08)..................................................................... 38

11 Warranty.................................................................................................................................. 3911.1 Information....................................................................................................................... 39

Table of Contents

2 e-HM Series Installation, Operation and Maintenance Manual

1 Introduction and Safety1.1 Introduction1.1.1 Purpose of this manual

This manual provides information on how to do the following in the correct manner:

• Installation• Operation• Maintenance.

CAUTION:

This manual is an integral part of the unit. Make sure to have read and understood themanual before installing the unit and putting it to use. The manual must always be madeavailable to the user, stored in the proximity of the unit, and well kept.

1.1.2 Supplementary instructionsThe instructions and warnings of this manual apply to the standard unit as described inthe sale documentation. Special version pumps may be supplied with supplementaryinstruction manuals. For situations not considered in the manual or in the sales document,contact Xylem or the Authorised Distributor.

1.2 Safety1.2.1 Danger levels and safety symbols

Before using the unit, the user must read, understand and comply with the indications ofthe danger warnings in order to avoid the following risks:

• Injuries and health hazards• Damage to the unit• Unit malfunction.

Danger levels

Hazard level Indication

DANGER: It identifies a dangerous situation which, if not avoided,causes serious injury, or even death.

WARNING: It identifies a dangerous situation which, if not avoided,may cause serious injury, or even death.

CAUTION: It identifies a dangerous situation which, if not avoided,may cause small or medium level injuries.

NOTICE: It identifies a situation which, if not avoided, may causedamage to property but not to people.

1 Introduction and Safety


Complementary symbols

Symbol Description

Electrical Hazard:

Electrical hazard

CAUTION:

Magnetic hazard

Hot Surface:

Hot surface hazard

1.2.2 User safetyStrictly comply with current health and safety regulations.

WARNING:

This unit must be used only by qualified users. Qualified users are people able torecognise the risks and avoid hazards during installation, use and maintenance of the unit.

Inexperienced users

WARNING:

For EU countries: this appliance can be used by children aged from 8 years and aboveand persons with reduced physical, sensory or mental capabilities or lack of experienceand knowledge, provided that they are being supervised and have been instructed on theuse of the appliance in a safe way and understand the hazards involved. Children shall notplay with the appliance. Cleaning and user maintenance shall not be carried out bychildren without supervision.

WARNING:

For countries outside the EU: this appliance is not intended for use by persons (includingchildren) with reduced physical, sensory or mental capabilities, or lack of experience andknowledge, unless they are being supervised and have been instructed on the use of theappliance by a person responsible for their safety. Children should be supervised toensure that they do not play with the appliance.

1.2.3 Protection of the environment

Disposal of packaging and product

Comply with the current regulations on sorted waste disposal.

Leaking of fluid

If the unit contains lubricating fluid, take appropriate measures to prevent the dispersionof leaks into the environment.



1.2.4 Sites exposed to ionizing radiations

WARNING: Ionizing radiation hazard

If the unit has been exposed to ionizing radiations, implement the necessary safetymeasures for the protection of people. If the unit needs to be despatched, inform thecarrier and the recipient accordingly, so that appropriate safety measures can be put inplace.



2 Transport and storage2.1 Handling of the packed unit

WARNING: Crushing hazard (limbs)

The unit and its components may be heavy: risk of crushing.

WARNING:

Always wear personal protective equipment.

WARNING:

Check the gross weight marked on the packaging.

WARNING:

Handle the unit in compliance with the current regulations on "manual load handling", toavoid undesirable ergonomic conditions causing risks of back-spine injury.

WARNING:

Take appropriate measures during transport, installation and storage to preventcontamination from external substances.

Depending on the model, the Manufacturer delivers the unit and its components in:

1. A cardboard box, or2. A cardboard box with wooden base.

The type 2 packaging is intended for transport with a forklift truck; the lifting points areindicated in the figure.

EHM

_M00

14_A

_ot1 2

Figure 1: Packed product lifting points

2 Transport and storage


2.2 Unit inspection upon delivery2.2.1 Inspect the package

1. Check that quantity, descriptions and product codes match the order.

2. Check the packaging for any damage or missing components.

3. In case of immediately detectable damage or missing parts:

– accept the goods with reserve, indicating any findings on the transport document,or

– reject the goods, indicating the reason on the transport document.

In both cases, promptly contact Xylem or the Authorised Distributor from whom theproduct was purchased.

2.2.2 Unpacking and inspection of the unit

CAUTION: Cut and abrasion hazard


1. Remove packing materials from the product.

2. Release the unit by removing the screws and/or cutting the straps, if fitted.

3. Check the unit for integrity and to make sure that there are no missing components.

4. In case of damage or missing components, promptly contact Xylem or the AuthorisedDistributor.

2.3 Unit handlingThe unit must be harnessed and lifted as shown in the figure.

EHM

_M00

15_A

_ot

Figure 2: Lifting of the unit

WARNING:

Use cranes, ropes, lifting straps, hooks and clasps that comply with current regulationsand that are suitable for the specific use.

NOTICE:

Make sure that the harnessing does not hit and/or damage the unit.



WARNING:

Lift and handle the unit slowly to avoid stability issues.

WARNING:

During handling, make sure to avoid injury to people and animals, and/or damage toproperty.

2.4 Storage2.4.1 Storage of the packed unit

The unit must be stored:

• In a covered and dry place• Away from heat sources• Protected from dirt• Protected from vibrations• At an ambient temperature between -40°C and +60°C (-40°F and 140°F), and relative

humidity between 5% and 95%.

NOTICE:

Do not place heavy loads on top of the unit.

NOTICE:

Protect the unit from collisions.

WARNING:


2.4.2 Long-term storage of the unit

1. Follow the same instructions for the storage of the packed unit.2. Empty the unit by removing the drain plug. This operation is essential in exceptionally

cold environments; any residual liquid in the unit could otherwise have an adverseeffect on its condition and performance.

EHM

_M00

09_A

_ph

Figure 3: Drain plug

For further information about preparation for long-term storage, please contact Xylem orthe Authorised Distributor.



3 Product Description3.1 Designation

Multistage horizontal centrifugal pump unit with threaded ports, non-self-priming.

3.2 Data plateThe data plate is a label showing:

• The main unit details• Identification code

11 12 13 14 15 16 17 18

19 110 111 112 113 114 115

EHM

_M00

03_A

_sc

Figure 4: Data plate

Positionnumber

Description

1 Head range

2 Flow rate

3 Pump unit type

4 Protection degree

5 Frequency

6 Power consumption

7 Serial number (date+progressive number)

8 Pump unit code

9 Maximum temperature of pumped liquid (for usage in compliance with EN 60335-2-41)

10 Maximum ambient operating temperature

11 Maximum operating pressure

12 Minimum head

13 Weight

14 Electrical data

15 Maximum temperature of pumped liquid (for usage outside the scope of EN 60335-2-41)

3 Product Description


11

EHM

_M00

04_A

_sc

1 0 H M E 0 3 S 1 5 M 0 2 V B E X X X / _

12 13 14 15 16 17 18 19 110 111 112 113 114 115

Figure 5: Identification code

Positionnumber

Description Notes

1 Rated flow rate 10 = m³/h

2 Series name HM

3 Motor operation Empty = standard asynchronous motorH = with Hydrovar®

X = other driversE = e-SM

4 Number ofimpeller

03 = 3 impellers

5 Material P = AISI 304 stainless steel with Noryl™ impellersS = AISI 304 stainless steelS = AISI 316 stainless steel

6 Motor ratedpower

kW x 10

7 Phase M = Single-phaseT = Three-phase

8 Power supplyvoltages

50 Hz standardasynchronous motor:5H = 1x220-240V5D = 1x110-120V5R =3x220-240/380-415V5V =3x380-415/660-690V5P =3x200-208/346-360V5S =3x255-265/440-460V5T =3x290-300/500-525V5W = 3x440-460/-V5Z1 = 3x500-525/-V

60 Hz standardasynchronous motor:6F = 1x220-230V6B = 1x110-115V6C = 120-127V6E = 1x200-210V6P =3x220-230/380-400V6R =3x255-277/440-480V6V = 3x440-480/-V6U =3x380-400/660-690V6L =3x110-115/190-200V6N =3x200-208/346-360V6T =3x330-346/575-600V6Z2 = 3x575/-V

Power supply e-SM:02 = 1x208-240V04 = 3x380-460V05 =3x208-240/380-460V

Asynchronous bi-frequency motor:BR = 3x230/400V 50Hz3x265/460 V 60 HzBV = 3x400/690V 50Hz3x460/-V 60Hz

9 Mechanical sealrotating part

Q = Silicon carbide(Q1)V = Aluminum oxide (ceramic)

10 Mechanical sealfixed part

Q = Silicon carbide(Q1)B = Resin impregnated carbon

1 For uses outside the scope of EN 60335-2-412 For uses outside the scope of EN 60335-2-41



Positionnumber

Description Notes

11 Elastomers E = EPDMV = FPMK = FFPM (Kalrez®)

12 Generalcharacteristics

Empty = noneA = Schuko plug + 3 m cableB = British standard plug + 2 m cableA = Australian standard plug + 2 m cableD = Documents or certificates on specific requestE = Passivated and electro-polishedF = Motor oversized by 2 sizesL = Seal housing + locking pinV = Air relief valveZ = other

13 Generalcharacteristics

Empty = noneP = PTC in the coilS = Condensation heaterD = Without condensation drain plugsU = UL approval (cURus)F = Mechanical seal internal flushingZ = Other, or several combined characteristics

14 Connections3 Null = ThreadedV = Victaulic®

Z = Other, or several combined characteristics

15 Null = NoneLetter assigned by the manufacturerOther = see technical catalogue

3.2.1 Marks of safety approvalThe presence of an electric safety approval mark, for example IMQ, TUV, IRAM, only refersto the pump unit.

3 In case of no further special configuration characters on the right, this character will be nil, otherwise it will be “X”



3.3 Denomination of the main components

EHM

_M00

01_A

_ds

12

7

8

69

10

3

2

1 411

5

18

19

Figure 6: Pump unit with close-coupled body

Positionnumber

Description Positionnumber

Description

1 Pump body 8 Elastomers

2 Impeller 9 Filling plug

3 Diffuser 10 Wear ring

4 Pump shaft 11 Drain plug

5 Motor adapter 12 Motor

6 Seal housing 18 Suction port

7 Mechanical seal 19 Discharge port



EHM

_M00

02_A

_ds

2

12

5

7

8

11

93

6

17

13

14

15

1610

4

18

19

Figure 7: Pump unit with body with sleeve

Positionnumber


Description

2 Impeller 11 Drain plug

3 Diffuser 12 Motor

4 Pump shaft 13 Shaft sleeve and bush

5 Motor adapter 14 Head

6 Seal housing 15 Ring with foot

7 Mechanical seal 16 Tie rod

8 Elastomers 17 Outer sleeve

9 Filling plug 18 Suction port

10 Wear ring 19 Discharge port

3.4 Intended use• Pressure boosting and water supply systems• Washing and cleaning sector, including washing of vehicles• Circulation of hot and cold liquids, for example water or water & glycol, for heating,

cooling and air conditioning systems• Water treatment applications• Handling of moderately aggressive liquids.

3.4.1 Pumped liquids• Hot water• Cold water



• Clean liquids• Fluids chemically and mechanically compatible with the materials of the pump unit.

Observe the operating limits in Technical references on page 34.

3.5 Improper useWARNING:

The unit was designed and built for the use described in the section Intended Use. Anyother use is prohibited, as it could compromise the safety of the user and the efficiency ofthe unit itself.

DANGER:

It is prohibited to use this unit to pump flammable and/or explosive liquids.

DANGER: Potentially explosive atmosphere hazard

It is prohibited to start the unit in environments with potentially explosive atmospheres orwith combustible dusts.

3.5.1 Examples of improper use• Pumping liquids not compatible with the construction materials of the unit• Pumping hazardous, toxic, explosive, flammable or corrosive liquids• Pumping drinking liquids other than water, for example wine or milk• Pumping liquids containing abrasive, solid, or fibrous substances• Using the unit for flow rates exceeding the flow rate indicated in the data plate.

3.5.2 Examples of improper installation• Explosive and corrosive atmospheres• Areas where the air temperature is very high and/or there is poor ventilation• Outdoor without protection from weather conditions.

3.6 Use in water distribution networks for human consumptionIf the unit is intended for water supply to people and/or animals:

WARNING:

It is prohibited to pump drinking water after use with other fluids.

WARNING:


WARNING:

Remove the unit from its packaging just before installation to prevent contamination fromexternal substances.



WARNING:

After installation, run the unit for a few minutes with several users open in order to washthe inside of the system.



4 Installation4.1 Precautions

Make sure you have read and understood the safety instructions in the Introduction andSafety chapter before starting work.

WARNING:


WARNING:

Always use suitable working tools.

WARNING:

When selecting the place of installation and connecting the unit to the hydraulic andelectric power supplies, strictly comply with current regulations.

When connecting the unit to a public or private aqueduct, or to a well for the supply ofwater for human and/or animal consumption:

WARNING:

It is prohibited to pump drinking water after use with other fluids.

WARNING:

Remove the unit from its packaging just before installation to prevent contamination fromexternal substances.

WARNING:

Observe all the provisions of the authorities and companies concerned.

4.2 Mechanical installation4.2.1 Installation area

• If possible, place the unit in a raised position in relation to the floor.• Make sure that any leaks will not cause flooding to the installation area or submerge

the unit.• Observe the instructions given in Operating environment on page 34.

Air clearance between a wall and the motor fan grille

• To ensure suitable ventilation: ≥ 100 mm.• To permit inspection and removal of the motor: ≥ 300 mm. If the space available is any

less, refer to the technical catalogue.

4 Installation


4.2.2 Permitted positions

EHM

_M00

05_A

_sc

Figure 8: Unit position

4.2.3 Fastening of the unit1. If present, remove the plugs covering the suction and discharge ports.

2. Place the unit on a level and sturdy surface.

3. Using a spirit level, make sure that the unit is level.

4. Align the suction and discharge ports to their piping.

5. Fasten the units using bolts (4 or 6 depending on the model), tightening at a torque of10 Nm (88 lbf-in).

NOTICE:

Only for models with body with sleeve, if the temperature of the pumped liquid exceeds50°C (122°F), only fasten bolts A; see the figure below.

EHM

_M00

13_A

_ph

A

B

Figure 9: Fastening of the unit

4.2.4 Reducing vibrationsThe motor and the flow of liquids in the pipes may cause vibrations, which can beexacerbated by incorrect installation of the unit and pipes. See Hydraulic connection onpage 18.

4 Installation


4.3 Hydraulic connectionDANGER:

All the hydraulic and electrical connections must be completed by a technicianpossessing the technical-professional requirements outlined in the current regulations.

WARNING:

Piping must be sized to ensure safety at the maximum operating pressure.

WARNING:

Install appropriate seals between the unit couplings and the pipings.

4.3.1 Guidelines for the hydraulic system

Refer to the representative hydraulic diagrams; see the figures below.

EHM

_M00

16_A

_sc

11

5 56

8

74 2 2 4

4 49

3

Q1

12

Figure 10: Positive suction head installation diagram

EHM

_M00

17_A

_sc

7

11

5

4

4 2 2

5

4

8

10

3

Q

4

91

13

Figure 11: Suction lift installation diagram

4 Installation


Positionnumber


Description

1 Pump unit 8 Electrode probes or float

2 Anti-vibration joint 9 Automatic relief valve

3 Overpressure safety on-off valve 10 Foot check valve with filter

4 On-off valve 11 Electric panel

5 Pressure gauge 12 Pressurised circuit

6 Minimum pressure switch 13 Filling on-off valve

7 Check valve

1. Do not install the unit at the lowest point of the system, to avoid the accumulation ofsediments.

2. Install an automatic relief valve at the highest point of the system to eliminate airbubbles.

3. Remove any welding residues, deposits and impurities in the pipes that could damagethe unit; install a filter if necessary.

4. Support the pipes independently to prevent them from weighing on the unit.

5. To reduce the transmission of vibrations between the unit and the system and viceversa, install:

– anti-vibration joints on the suction and discharge sides of the unit– dampers between the unit and the surface on which it is installed.

6. In order to reduce flow resistance, the pipe on the suction side must be:

– As short and as straight as possible– For the section connected to the unit, straight and without bottlenecks, covering a

length equal to at least six times the diameter of the suction port– Wider than the suction port; if necessary, install an eccentric reducer that is

horizontal on top– Without bends; if this cannot be avoided, bends of a radius as wide as possible– Without traps and 'goosenecks'– With valves with a low specific flow resistance.

EHM

_M00

08_A

_sc

7. Install a check valve on the discharge side to prevent the liquid from flowing back intothe pump unit when this is at standstill.

8. Install a pressure gauge (or a vacuum pressure gauge, in the case of suction liftinstallation) on the suction side, and a pressure gauge on the discharge side, forchecking the actual operating pressure of the pump unit.

9. To exclude the unit from the system for the purpose of maintenance, install:

– An on-off valve on the suction side– An on-off valve on the discharge side, downstream of the check valve and pressure

gauge, also useful for regulating the flow rate.

10.On the suction side, install a device to prevent the absence of liquid (float or probes),or a minimum pressure device.

11.Sufficiently submerge the end of the suction pipe in the liquid, in order to prevent anyair from penetrating through the suction vortex when the level is at the minimum.

12.In case of suction lift installation, the suction pipe must have an increasing slopetowards the unit exceeding 2%; to avoid air pockets; also install:

4 Installation


– A foot valve that guarantees full opening (full section)– A filling on-off valve to facilitate the removal of the air and priming.

4.4 Electrical connectionDANGER:

All the hydraulic and electrical connections must be completed by a technicianpossessing the technical-professional requirements outlined in the current regulations.

DANGER: Electrical hazard

Before starting work, check that the unit is unplugged and that the pump unit, the controlpanel and the auxiliary control circuit cannot restart, even unintentionally.

4.4.1 Ground


Always connect the external protection conductor (ground) to the ground terminal beforeattempting to make any other electrical connections.


Connect all the electrical accessories of the pump unit and motor to the ground.


Check that the external protection conductor (ground) is longer than the phaseconductors; In case of accidental disconnection of the unit from the phase conductors, theprotection conductor must be the last one to detach itself from the terminal.


Install suitable systems for protection against indirect contact, in order to prevent lethalelectric shocks.

4.4.2 Guidelines for electrical connection1. Check that the electrical leads are protected against:

– High temperature– Vibrations– Collisions.

2. Check that the power supply line is provided with:

– A short circuit protection device of appropriate size– A mains isolator switch with a contact gap of at least 3 mm.

4.4.3 Guidelines for the electric panel

NOTICE:

The electric panel must match the ratings on the unit data plate. Improper combinationscould damage the motor.

4 Installation


1. The electric panel must protect the motor against overloading and short circuits; installa suitable device (thermal relay or overload cut-out switch; see the table)

2. Fit the electric panel with a system for protection against dry running to which apressure switch (or float switch, probes, or other suitable devices) must be connected.

3. Install these devices on the suction side:

– A pressure switch, in the case of connection to the mains water supply– A float switch or probes, in the case of liquid drawn from a tank or basin.

4. When thermal relays are used, the type sensitive to phase failure is recommended.

Table 1: Motor protection devices

Pump unit Protection

Single phase standard≤ 1.5 kW

• Automatic reset thermal-ampere protection, in-built (motorprotector)

• From short circuit, to be supplied by the installer4.

Three-phase andsingle-phase5

• Thermal, must be supplied by the installer• Short circuit, must be supplied by the installer.

4.4.4 Motor guidelines

WARNING: Injuries hazard

The unit, equipped with a single-phase motor with automatic reset thermal overloadprotection, could restart inadvertently after it has cooled down: risk of physical injury.

1. Open the terminal box cover.

2. Connect the power supply conductor; see the figure below, or the wiring diagramshown inside the terminal box cover.

3. Connect the protection conductor (ground), making sure that it is longer than thephase conductors.

4. Connect the phase leads.

5. Close the terminal box cover and tighten all the screws and cable glands.

EHM

_M00

06_A

_sc

1~ 3~A BA

B

Figure 12: Electrical connection and tightening torques

4 aM fuses (motor start-up), or thermal magnetic switch with C curve and Icn ≥ 4.5 kA, or other similar device5 Trip class 10 A overload thermal relay + aM fuses (motor starting), or start class 10 A motor protection thermal magnetic switch

4 Installation


A B

Wrench [mm] M4 M5 M6 M8 M10 -

Tighteningtorque [Nm] /[lbf·in]

1,2 / 11 2,5 / 22 4,0 / 35 8,0 / 71 15,0 / 133 1,2 / 11

Motor without automatic reset thermal overload protection

1. If the motor is used with full load, then set the value to the nominal current value onthe data plate of the pump unit.

2. If the motor is used with partial load, then set the value of the operating currentmeasured with a current pincer.

3. For three-phase motors with star-delta starting system, set the thermal relaydownstream of the switching circuit at 58% of the rated or operating current.

4.4.5 Operation with frequency converterThe three-phase motors can be connected to a frequency converter for speed control.

• The converter exposes the insulation of the motor to a greater load determined by thelength of the connecting cable: observe the requirements of the Manufacturer of thefrequency converter

• For applications requiring silent operation, install an outlet filter between the motorand the converter; a sinusoidal filter can reduce the noise even further

• The bearings of the motors, from size 315 S/M and up, are exposed to the risk ofharmful currents: use electrically insulated bearings.

• The conditions of installation must guarantee protection against voltage peaksbetween the terminals and/or dV/dt in the table:

Motor size Voltage peak [V] dV/dt [V/µs]

up to 90R (500 V) > 650 > 2200

from 90R to 180R > 1400 > 4600

over 180R > 1600 > 5200

Otherwise, use a motor with reinforced insulation 6and a sinusoidal filter.

6 Available on request

4 Installation


5 Operation5.1 Precautions


Check that the protection devices of the coupling are installed, when applicable: risk ofphysical injury.

WARNING:

Make sure that the drained liquid cannot cause damage or injuries.

WARNING: Electrical hazard

Check that the unit is properly connected to the mains power supply.


The unit, equipped with a single-phase motor with automatic reset thermal overloadprotection, could restart inadvertently after it has cooled down: risk of physical injury.

WARNING: Hot surface hazard

Be aware of the extreme heat generated by the unit.

WARNING:

It is prohibited to put combustible materials near the unit.

NOTICE:

Check that the shaft can turn smoothly.

NOTICE:

It is prohibited to operate the unit when dry, not primed and below the minimum ratedflow rate.

NOTICE:

it is prohibited to operate the unit with the on-off valves on the suction and dischargesides closed.

NOTICE:

It is prohibited to use the unit in the case of cavitation.

NOTICE:

The unit must be filled and vented properly before it can be started.

5 Operation


NOTICE:

The maximum pressure of the unit at the discharge, at the discharge side, determined bythe pressure available on the suction side, must not exceed the maximum pressure (PN).

5.2 Filling - Priming

NOTICE:

The unit must be filled and vented properly before it can be started.

5.2.1 Positive suction head installation

WARNING:

In the case of liquids that are excessively hot or cold, pay attention to the risk of injury.

1. Close the on-off valve on the suction (C) and discharge (A) side.

2. Loosen the filling plug (B).

3. Slowly open the on-off valve (C) until the liquid regularly comes out from the fillinghole; if necessary, loosen the plug further (B).

4. Replace the plug (B).

5. Open both the on-off valves slowly and fully.

Figure 13: Positive suction head installation priming

5.2.2 Suction lift installation

WARNING:


1. Close the on-off valve (A) on the discharge side.

2. Remove the filling plug (B).

3. Fill the pump unit until the liquid comes out of the hole.

4. Wait a few minutes and top up with more liquid if necessary.

5. Remove any air that might be present through the relief valve of the suction pipes (see Guidelines for the hydraulic system on page 18).

6. Replace the plug (B).

5 Operation


Figure 14: Suction lift installation priming

5.3 Checking the direction of rotation (three-phase motors)Before starting the pump unit:

NOTICE:


1. Locate the arrows on the adapter, coupling or cover to determine the correct directionof rotation of the motor.

2. Start the pump unit.

3. Check the direction of rotation through the coupling protection or through the motorcover

4. Stop the pump unit.

Figure 15: Motor rotation direction

5.3.1 Wrong rotation direction1. Disconnect the power supply.

2. Invert two of the three wires of the power cable in the terminal box of the motor or inthe control panel.

3. Connect the power supply.

4. Start the pump unit.

5. Check the direction of rotation through the coupling protection, or through the motorfan cover

6. Stop the pump unit.

5 Operation


5.4 Start-up

NOTICE:

It is prohibited to operate the unit with the discharge on-off valve closed or at zero flowrate: this can cause the liquid to overheat and damage the unit.

NOTICE:

If there is a risk of the unit running at a flow rate below the minimum expected, install abypass circuit.

NOTICE:


1. Check that all the operations indicated in Filling - Priming on page 24 and Checkingthe direction of rotation (three-phase motors) on page 25 have been completedcorrectly.

2. Shut off the discharge on-off valve almost completely.

3. Fully open the suction on-off valve.

4. Start the unit.

5. Gradually open the on-off valve on the discharge side until it is half open.

6. Wait a few minutes and then fully open the discharge on-off valve.

After the start-up procedure, with the pump unit in operation, check that:

• No liquid is leaking from the unit or pipes• The maximum pressure of the unit at the discharge, at the discharge side, determined

by the pressure available on the suction side, must not exceed the maximum pressure(PN)

• The current absorbed is within the rated limits (calibrate the thermal overloadprotection of the motor)

• There is no unwanted noise or vibrations• At zero flow rate, the pressure at the discharge corresponds to the expected nominal

pressure• No vortexes can occur at the end of the suction pipe, at the point of the foot check

valve (suction lift installation).

NOTICE:

If the units does not deliver the required pressure, repeat the operations in Filling -Priming on page 24.

WARNING:

After startup, run the unit for a few minutes with several users open in order to wash theinside of the system.

5.4.1 Settling of the mechanical seal

The pumped liquid lubricates the seal faces of the mechanical seal; under normalconditions, a small amount of liquid may leak out. When the unit is run for the first time, orimmediately after the seal is replaced, more liquid may temporarily leak out. To help theseal settle and to reduce leaking:

1. Close and open the on-off valve on the discharge line two or three times with the unitrunning.

2. Stop and start the unit two or three times.

5 Operation


5.5 Stopping1. Shut the on-off valve located on the discharge line.

2. Stop the pump unit and check that the motor slows down gradually.

3. Gradually re-open the on/off valve and check that the motor remains still.

5 Operation


6 Maintenance6.1 Precautions

Make sure to read and understand the safety instructions before starting work.

WARNING:

Maintenance must be done by a technician possessing the technical-professionalrequirements outlined in the current regulations.

WARNING:


WARNING:

Always use suitable working tools.

WARNING:



Before starting work, check that the unit is unplugged and that the pump unit, the controlpanel and the auxiliary control circuit cannot restart, even unintentionally.


If the unit is connected to the frequency converter, disconnect the mains power supplyand wait at least 10 minutes for the residual current to dissipate.

6.2 Maintenance every 4000 hours of operation or every yearWhen the first of the two limits is reached:

1. Measure the pressure at zero flow rate and compare it with the pressure measuredduring initial start-up; if the pressure has decreased by more than 15%, check thecondition of impeller, pump body and wear rings.

2. Check the unit for unwanted noise and vibrations.

3. Check that there is no liquid leaking from the unit or pipes.

4. Check that all the screws and bolts of the unit and pipes are properly fastened.

5. Check that the insulation resistance of the motor is greater than 500 MΩ, applying atest voltage of 500 Vdc for 1 minute.

6. Check the terminal board of the motor for any signs of overheating and arc flashes.

7. Check the condition of the motor's cooling fan and clean it.

6 Maintenance


6.3 Long periods of inactivity1. Close the on-off valve on the suction side.

2. Completely empty the unit.

3. Protect the unit against freezing.

4. Before restarting the unit, check that the shaft is rotating freely, without mechanicalimpediments.

6.4 Ordering spare partsIdentify the spare parts with the product codes directly on the site www.lowara.com/spark.

Contact Xylem or the Authorised Distributor for technical information.

6 Maintenance


7 Troubleshooting7.1 Precautions

WARNING:

Maintenance must be done by a technician possessing the technical-professionalrequirements outlined in the current regulations.

WARNING:

Observe the safety requirements in the chapters on Operation and Maintenance.

WARNING:

If a fault cannot be corrected or is not mentioned, contact Xylem or the AuthorisedDistributor.

7.2 The unit does not startCause Remedy

Power supply cut off Restore the power supply

The thermal overload protection of the motor has beentriggered

Reset the thermal overload protection on the controlpanel or the unit

The device that detects the absence of liquid or minimumpressure has been triggered

Top up the liquid or restore minimum pressure

Power supply cable is damaged Replace the power supply cable

The capacitor, if present, is faulty Replace the capacitor

Control panel faulty Check and repair or replace the control panel

Motor (coil) faulty Check and repair or replace the motor

7.3 The differential protection device (RCD) is activatedCause Remedy

Motor leaking Check and repair or replace the motor

Unsuitable type of differential Check the type of differential

7.4 The motor thermal overload protection or the fuses triggerwhen the unit starts

Cause Remedy

It is calibrated at a value too low in relation to the ratedcurrent of the motor

Recalibrate

Missing power supply phase Check the power supply and restore the phase

Loose and/or faulty connections of the thermal overloadprotection

Tighten or replace the clamps and terminals

Loose and/or incorrect and/or faulty (star-delta)connections in the terminal board of the motor

Tighten or replace the clamps and terminals

Motor (coil) faulty Check and repair or replace the motor

7 Troubleshooting


Cause Remedy

Pump unit mechanically seized up Check and repair the unit

Power supply cable is damaged Replace the power supply cable

Check valve faulty Replace the check valve

Foot check valve faulty Replace the foot check valve

7.5 The thermal motor protection tripsThe motor thermal overload protection triggers occasionally, or after the unit has beenrunning for a few minutes

Cause Remedy

It is calibrated at a value too low in relation to the ratedcurrent of the motor

Recalibrate

Input voltage outside the rated limits Make sure the voltage values are correct

Unbalanced input voltage Make sure the voltage of the three phases is balanced

Incorrect working curve (flow rate greater than themaximum permitted flow rate)

Reduce the required flow rate

Liquid too dense, presence of solid or fibrous substances(unit overloaded)

• Reduce the density of the liquid and/or• Remove the solid substances and/or• Increase the size of the motor

Room temperature too high, exposure to sunlight • Lower the temperature at the point of the thermaloverload protection and/or

• Protect against direct sunlight

Unit faulty Send the unit to an authorised workshop for testing

7.6 The unit runs but there is little or no flow rateCause Remedy

Motor turns in the wrong direction Check the direction of rotation and change it if necessary

Incorrect priming (there are air bubbles in the suctionpipe or in the unit)

Repeat the priming procedure

Cavitation Increase the NPSH7 available in the system

Check valve locked in closed or partially closed position Replace the check valve

Foot check valve locked in closed or partially closedposition

Replace the foot check valve

Discharge pipe throttled Remove the throttling

Piping and/or unit clogged Remove the clogging

7.7 When turned off, the unit turns in the opposite directionCause Remedy

Check valve faulty Replace the check valve

Foot check valve faulty Replace the foot check valve

7.8 The unit produces excessive noise and/or vibrationsCause Remedy

Cavitation Increase the NPSH8 available in the system

7 Net Positive Suction Head8 Net Positive Suction Head

7 Troubleshooting


Cause Remedy

Unsuitable anchoring to the ground Check the anchoring to the ground

Resonance Check the installation

Anti-vibration joints not installed Install anti-vibration joints on the suction and dischargesides of the unit

Foreign bodies in the unit Remove the foreign bodies

Motor bearings worn or faulty Replace the motor bearings

The unit does not turn freely due to a mechanical fault Send the unit to an authorised workshop for testing

7.9 The unit starts up too frequently (automatic start/stop)Cause Remedy

Incorrect priming (there are air bubbles in the suctionpipe or in the unit)

Repeat the priming procedure

Check valve locked in closed or partially closed position Replace the check valve

Foot check valve locked in closed or partially closedposition

Replace the foot check valve

Starting device (pressure switch, sensor, etc.) setincorrectly or faulty

Adjust or replace the starter

Expansion vessel• no pre-charge, or• undersized, or• not installed

• Pre-charge the expansion vessel, or• replace the expansion vessel with another suitable

one, or• install an expansion vessel

Oversized unit Contact Xylem or the Authorised Distributor

7.10 The unit never stops (automatic start/stop)Cause Remedy

The required flow rate is greater than the one expected Reduce the required flow rate

Discharge pipe leaking Eliminate the leaks

Motor turns in the wrong direction Check the direction of rotation and change it if necessary

Pipes, on-off valves or filter clogged with impurities Remove the impurities

Starting device (pressure switch, sensor, etc.) setincorrectly or faulty

Adjust or replace the starter

The unit runs but there is little or no flow rate See The thermal motor protection trips on page 31.

7.11 The unit is leakingCause Remedy

Worn mechanical seal • Replace the mechanical seal, or• Fit a mechanical seal with harder seal faces

Mechanical seal damaged due to thermal shock(presence of air bubbles in the unit)

Replace the mechanical seal

Defective mechanical seal Replace the mechanical seal

Mechanical seal damaged due to temperature of theliquid outside the rated limits

Replace the mechanical seal with another of a suitablemake

Mechanical seal damaged due to chemicalincompatibility with the liquid

Replace the mechanical seal with a model chemicallycompatible with the pumped liquid

7 Troubleshooting


7.12 The motor becomes excessively hotCause Remedy

Room temperature outside the rated limits Lower the room temperature

Cooling fan of the motor clogged or damaged Clean or replace the cooling fan

The unit starts up too frequently See The unit produces excessive noise and/or vibrationson page 31

The frequency converter, if present, has not beencalibrated properly

See the frequency converter manual

7.13 The frequency converter (if present) is in error mode or turnedoff

Cause Remedy

See the frequency converter manual See the frequency converter manual

7 Troubleshooting


8 Technical references8.1 Operating environment

Non-aggressive and non-explosive atmosphere.

8.1.1 Temperature

Phase ~ Min. temperatureto max. [°C] /[°F]

Notes

1 -15 to 45 / 5 to 113

-15 to 40 / 5 to 104 Only for models 1HM06S/N, 3HM03S/N, 3HM02P, 5HM02S/Nand with 0.95 kW motor

3 -15 to 50 / 5 to 122

8.1.2 Relative air humidity< 50% at +40°C (104°F).

8.1.3 Elevation< 1000 m (3280 ft) above sea level.

NOTICE:

If the temperature and humidity exceed the stated limits, contact Xylem or the AuthorisedDistributor.

NOTICE:

If the unit is installed at an altitude greater than the stated one, reduce the power outputof the motor according to the coefficients below, or replace it with a more powerful one.

Table 2: Motor power reduction coefficient

Altitude [m] / [ft] Ambient temperature [°C] / [°F]

0 / 32 10 / 50 20 / 68 30 / 86 40 / 104 45 / 113 50 / 122 55 / 131 60 / 140

0 / 0 1.00 1.00 1.00 1.00 1.00 0.95 0.90 0.85 0.80

500 / 1640 1.00 1.00 1.00 1.00 1.00 0.95 0.90 0.85 0.80

1000 / 3280 1.00 1.00 1.00 1.00 1.00 0.95 0.90 0.85 0.80

1500 / 4921 0.97 0.97 0.97 0.97 0.97 0.92 0.87 0.82 0.78

2000 / 6561 0.95 0.95 0.95 0.95 0.95 0.90 0.85 0.80 0.76

8.2 Temperature of pumped liquidThe pressure-temperature diagram in the figure shows the operating limits of the unit.Contact Xylem or the Authorised Distributor for special needs.

8 Technical references


EHM

_M00

07_A

_ot

-40 -20 0 20 40 60 80 100 120 140 t [°C]

-40 -4 32 68 104 140 176 212 248 284 t [°F]

20

15

10

5

0

p [bar] VB.. Q1Q1..Q1B..

EPDM

KALREZ

FPM

Figure 16: Temperature-pressure diagram

8.3 Operating pressureSee Temperature of pumped liquid on page 34 for the maximum operating pressure, forthe unit model and the temperature of the pumped liquid:

P1max +P max ≤ PN

P1max= Maximum input pressure

Pmax= Maximum generated pressure

PN= Maximum operating pressure

8.4 Maximum hourly start-upsUnit rated power [kW] 0.25 to 3 4 to 7.50 11 to 15 18.5 to 22 30 to 37 45 to 75 90 to 160

No. of start-ups at regularintervals per h

60 40 30 24 16 8 4

8.5 Protection classIP 55.

8.6 Electrical specificationsSee the motor data plate.

8.7 Permitted tolerances for the supply voltageFrequency [Hz] 50 60

Phase ~ 1 3 1 3

UN [V] ± % 220 to 240 ± 6 230/400 ± 10400/690 ± 10

220 to 230 ± 6 220/380 ± 5380/660 ± 10

No. of conductors +earth

2+1 3+1 2+1 3+1

8.8 Noise levelThe free field LA sound pressure level measured at a distance of one metre from the unitis less than 70 dB (A).



Power [kW] 0.3 0.4 0.50 0.55 0.75 0.95 1.1 1.5 2.2 3 4 5.5

LA noise level [dB±3] 52 52 52 55 55 55 60 60 60 60 60 60

8.9 MaterialsThe table shows the materials in contact with the liquid.

Code Material

Pump body Impellers Diffusers

HM..P Stainless steel/AISI 304 Technopolymer Stainless steel/AISI 304

HM..S Stainless steel/AISI 304 Stainless steel/AISI 304 Stainless steel/AISI 304

HM..N Stainless steel/AISI 316 Stainless steel/AISI 316 Stainless steel/AISI 316



9 Disposal9.1 Precautions

WARNING:

The unit must be disposed of through approved companies specialised in theidentification of different types of materials (steel, copper, plastic, etc.)

WARNING:

It is prohibited to dispose of lubricating fluids and other hazardous substances in theenvironment.

9 Disposal


10 Declarations10.1 EC Declaration of Conformity (Original)

Xylem Service Italia S.r.l., with headquarters in Via Vittorio Lombardi 14 - 36075Montecchio Maggiore VI - Italy, hereby declares that the product:

pump unit (see label on SAFETY manual)

fulfils the relevant provisions of the following European Directives:

• Machinery 2006/42/EC (ANNEX II - natural or legal person authorised to compile thetechnical file: Xylem Service Italia S.r.l.)

• Eco-design 2009/125/EC, Regulation (EC) No 640/2009 & Regulation (EU) No 4/2014(Motor 3 ~, 50 Hz, PN ≥ 0.75 kW) if IE2 or IE3 marked,

and the following technical standards

• EN 809:1998+A1:2009, EN 60335-1:2012+A11:2014, EN60335-2-41:2003+A1:2004+A2:2010, EN 62233:2008

• EN 60034-30:2009, EN 60034-30-1:2014

Montecchio Maggiore, 11.03.2016

Amedeo Valente

(Director of Engineering and R&D)

rev.02

10.2 EU Conformity Declaration (n. EMCD08)1. Product / Device model: (see label on SAFETY manual)2. Name and address of the manufacturer: Xylem Service Italia S.r.l. - Via Vittorio

Lombardi 14 -36075 Montecchio Maggiore VI - Italy3. This declaration of conformity is issued under the sole responsibility of the

manufacturer.4. Object of the declaration: Pump Unit5. The object of the declaration described above is in conformity with the relevant Union

harmonization legislation: 2014/30/EU Directive of 26 February 2014 (electromagneticcompatibility)

6. References to the relevant harmonized standards used or references to the othertechnical specifications, in relation to which conformity is declared: EN61000-6-1:2007, EN 61000-6-3:2007+A1:2011

7. Notified body: -8. Additional information:

Signed for and on behalf of: Xylem Service Italia S.r.l.

Montecchio Maggiore, 11.03.2016

Amedeo Valente

(Director of Engineering and R&D)

rev.00

Lowara is a trademark of Xylem Inc. or one of its subsidiaries.

10 Declarations


11 Warranty11.1 Information

For information on the warranty refer to the documentation of the sale contract.

11 Warranty


Xylem |’zīləm|

1) The tissue in plants that brings water upward from the roots;2) a leading global water technology company.

We’re a global team unified in a common purpose: creating advancedtechnology solutions to the world’s water challenges. Developing newtechnologies that will improve the way water is used, conserved, and re-used inthe future is central to our work. Our products and services move, treat, analyze,monitor and return water to the environment, in public utility, industrial,residential and commercial building services settings. Xylem also provides aleading portfolio of smart metering, network technologies and advancedanalytics solutions for water, electric and gas utilities. In more than 150 countries,we have strong, long-standing relationships with customers who know us for ourpowerful combination of leading product brands and applications expertise witha strong focus on developing comprehensive, sustainable solutions.

For more information on how Xylem can help you, go to www.xylem.com

Xylem Service Italia S.r.l.Via Vittorio Lombardi 14 Montecchio Maggiore (VI) 36075 Italy

Visit our Web site for the latest version of this documentand more information

The original instruction is in English. All non-Englishinstructions are translations of the original instruction.

© 2018 Xylem Inc

Cod.001080056EN rev.F ed.09/2018

http://www.xylem.com